Compact absorbent article

ABSTRACT

A disposable absorbent article which is compactly packaged is provided, which has a folded configuration and an unfolded configuration. A ratio between the folded configuration and the unfolded configuration is less than 0.09.

BACKGROUND OF THE INVENTION

[0001] The present invention relates to a packaging of disposableabsorbent articles. More particularly, the present invention relates topackaging of disposable absorbent articles such as diapers, trainingpants, adult incontinence products/garments, and so forth.

[0002] Absorbent articles such as, for example, diapers, training pantsand incontinence garments desirably provide a comfortable fit about thewearer and contain body exudates. Such absorbent articles arecommercially packaged in packages which include multiple articlestherein.

[0003] Conventional diapers contained in a package are often folded suchthat each longitudinal side is folded inward, toward the crotch, andthen the diaper is folded once, at the center so that it overlapsitself. Training pants and incontinence garments are often alreadyconfigured to resemble underwear for the lower torso. These articles arealso provided with few folds when positioned in a package of likeproducts. Therefore, individual articles are relatively large andconsume considerable space. Diapers and training pants are often carriedin a diaper bag to accommodate a caregiver carrying a number of sucharticles. Incontinence garments are sized for adults, and present agreater problem regarding space and the desire to carry such garments ina discrete and confidential manner.

[0004] The disposable absorbent articles described above each contain anabsorbent web which includes some amount of cellulosic absorbentmaterial. Efforts to package one or a few such articles in a small,compact package have resulted in detrimental effects to the absorbentcapabilities of the cellulosic and other absorbent material(s). This isbecause cellulosic material has little resiliency under certain normalconditions, and too much pressure or compression under those normalconditions removes the resiliency, resulting in stiffness and areduction in performance. Such articles therefore have had anundesirable effect on ease of application, poorer fit, and are morelikely to have an increase in undesirable leakage of exudates.

[0005] Continued space and modesty considerations, however, illustratethat a need exists for a compact package containing a single article, orseveral articles, which is provided in a much smaller, compactconfiguration compared to its expanded use configuration. Such anarticle's performance desirably would not be substantially affected byits compact packaged configuration. When such an article was removedfrom its package and placed into its un-compacted use configuration, itwould desirably provide the same performance via ease of application,fit, and absorbency and containment of exudates as an un-compactedarticle. Such a compact packaged article would desirably be sized to fitinto a purse, or a standard shirt or pants pocket.

SUMMARY OF THE INVENTION

[0006] In response to the difficulties and problems discussed above, adisposable absorbent article is provided. The disposable absorbentarticle has a folded configuration and an unfolded configuration. Aratio between the folded configuration and the unfolded configuration isless than 0.09.

[0007] In another aspect of the invention, a compact packaged disposableabsorbent article includes a disposable absorbent article. Thedisposable absorbent article has a folded configuration and an foldedconfiguration. A ratio between the folded configuration and the unfoldedconfiguration is less than 0.12. The compact disposable absorbentarticle also includes a package. The package has a gas permeability in arange of less than about 5.0 cc/100 in²/24 hours to about 0.05 cc/100in²/24 hours. The disposable absorbent article is folded to have morethan three overlapping folds in its folded configuration. It ismaintained and packaged in the package at a moisture content of lessthan 5 percent.

[0008] It is to be understood that both the foregoing generaldescription and the following detailed description are exemplary and areintended to provide further explanation of the invention claimed. Theaccompanying drawings, that are incorporated in and constitute part ofthis specification, are included to illustrate and provide a furtherunderstanding of the articles and methods of the invention. Togetherwith the description, the drawings serve to explain various aspects ofthe invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The present invention will be more fully understood and furtheradvantages will become apparent when reference is made to the followingdetailed description of the invention and the accompanying drawingswherein like numerals represent like elements. The drawings are merelyrepresentative and are not intended to limit the scope of the appendedclaims.

[0010]FIG. 1 representatively shows a plan view of one embodiment of adisposable absorbent article in an unfastened, laid flat withunretracted elastics and extended to ungathered length configurationwith the surface of the article which contacts the wearer's clothingfacing the viewer and with portions of the article partially cut away toshow the underlying features;

[0011]FIG. 2 representatively shows a perspective view of the absorbentarticle in a fastened configuration, generally similar to theconfiguration of the disposable absorbent article when it is fastenedabout a lower torso of a wearer;

[0012]FIG. 3 representatively shows a plan view of the absorbent articlein which each side is folded over the center;

[0013]FIG. 4 representatively shows a perspective view of the absorbentarticle of FIG. 3 folded into a bifolded configuration;

[0014]FIG. 5 representatively shows a perspective view of the absorbentarticle of FIG. 3 folded into a trifolded configuration;

[0015]FIG. 6 representatively shows a perspective view of the absorbentarticle of FIG. 4 folded into a quadrifolded configuration;

[0016]FIG. 7 representatively shows a perspective view of the absorbentarticle of FIG. 4 having each end folded over a center to providegenerally an “S” configuration;

[0017]FIG. 8 representatively shows a perspective view of the absorbentarticle of FIG. 4 which has each end folded inward to provide generallya “Pretzel” configuration;

[0018]FIG. 9 representatively shows a perspective view of the absorbentarticle of FIG. 3 which has been rolled into a generally cylindricalconfiguration;

[0019]FIG. 10 is a schematic representation of an apparatus forpackaging disposable absorbent articles;

[0020] FIGS. 11A-11C representatively shows different embodiments ofpackages in which disposable absorbent articles may be packaged inaccordance with the present invention;

[0021]FIG. 12 representatively shows a perspective view of a child'straining pant; and

[0022]FIG. 13 representatively shows a perspective view of an adultincontinence pant or garment.

DETAILED DESCRIPTION OF THE INVENTION

[0023] Reference will now be made in detail to one or more embodimentsof the invention, examples of which are illustrated in the drawings.Each example and embodiment is provided by way of explanation of theinvention, and not meant as a limitation of the invention. For example,features illustrated or described as part of one embodiment may be usedwith another embodiment to yield still a further embodiment. It isintended that the invention include these and other modifications andvariations as coming within the scope and spirit of the invention.

[0024] It has been discovered that disposable absorbent articles, suchas, by way of non-limiting example, a single disposable diaper, a singletraining pant, and a single adult incontinence pant or garment, may becompactly folded and packaged to provide a much smaller configuration or“footprint” when compared to its unfolded configuration or footprint,without compromising softness or absorbency. Cellulose and some superabsorbent materials or particles (hereinafter collectively “SAP” or“SAPs”), such as, for example, partially neutralized and crosslinkedpolyacrylate, used in disposable absorbent articles hydrogen bond whenbrought in close proximity under certain normal conditions, such as whenpressured or compressed when too moist, or when exposed to excessiverelative humidity in the surrounding atmosphere while under a conditionof being compressed. By controlling the moisture content of theabsorbent core, temperature and pressure properly, it has beendiscovered that hydrogen bonding materials, such as, by way ofnon-limiting example, cellulose and SAPs, may be compactly folded andpackaged for weeks, months, or years, yet still retain resiliency andperformance when un-packaged for use without being stiff or having asignificant reduction in the performance of the disposable absorbentarticle.

[0025] The unfolded configuration or footprint, as used herein refers toan absorbent disposable article, such as a diaper, positioned in itsunfastened, laid flat with unretracted elastics and extended toungathered lengths configuration, as best represented in FIG. 1.Similarly, a pant-type disposable absorbent article 10, such as atraining pant or an adult incontinence pant or garment is positioned byfirst cutting the article from each leg opening to the waist opening oneach side (if the pant/garment is not provided with pre-existingopenings in these areas), and positioning the article 10 in the unfoldedand laid flat position described above. The folded compact configurationor footprint, as used herein, refers to a disposable absorbent article,such as a diaper, positioned in its folded compact position. Additionaldetails of both configurations or footprints will be discussed in detailbelow. Methods of restraining and packaging such articles, such as, byway of non-limiting example, vacuum packaging, in combination withcertain folding procedures and construction of the article, have beendiscovered. The results are a packaged compact disposable absorbentarticle that, when removed from its package, has substantially the sameabsorbency as those articles which have not been folded and packaged ina compact manner.

[0026] The compact absorbent articles of the present invention mayinclude other types of absorbent articles, such as adult incontinentproducts, training pants, other personal care or health care garments,diaper pants and other types of garment-style disposable absorbentarticles. Diapers are disclosed in U.S. Pat. No. 4,704,116 to Enloe,U.S. Pat. No. 4,050,462 to Woon et al., U.S. Pat. No. 5,383,872 toRoessler et al., U.S. Pat. No. 6,028,240 to Wessel et al., U.S. Pat. No.6,316,687 to Davis et al., and U.S. Pat. No. 6,443,938 to Vogt, all ofwhich are incorporated by reference herein. Training pants are disclosedin U.S. Pat. No. 4,641,381 to Heran et al., U.S. Pat. No. 4,646,362 toHeran et al., U.S. Pat. No. 5,766,389 to Brandon et al., and U.S. Pat.No. 6,297,424 to Olson et al., all of which are incorporated herein byreference in their entirety. Adult incontinence products are disclosedin U.S. Pat. No. 4,630,320 to Van Gompel, U.S. Pat. No. 4,886,512 toDamico et al., U.S. Pat. No. 5,651,778 to Melius et al., U.S. Pat. No.6,260,211 to Rajala et al., and U.S. Pat. No. 6,387,085 to Van Gompel etal., all of which are incorporated herein by reference in theirentirety.

[0027] Specifically, the present invention is directed toward disposablefolded compact absorbent articles which are used at least, but not byway of limitation, to absorb urine, and which are designed to cover atleast a portion of a lower torso when worn by a wearer. That is, thearticle is configured to extend about the circumference of the lowertorso and between the legs of a wearer when worn. It will beappreciated, however, that descriptions, figures, examples, test(s), andso forth of a particular packaged compact disposable article, such as adiaper, are only by way of example, and are intended as non-limiting inthe scope and spirit of the invention.

[0028] An embodiment of a disposable absorbent article 10, isillustrated in FIG. 1, in this instance, a diaper 20. FIG. 12 showsanother example of a disposable absorbent article 10, in this instance,a child's training pant 200. FIG. 13 illustrates yet another example ofa disposable absorbent article 10, in this instance, a refastenableadult incontinence pant or garment 300.

[0029] Turning now, however, to FIG. 1, the diaper 20 is shown in anunfastened, laid flat with unretracted elastics and extended toungathered length configuration with the surface of the diaper 20adapted to contact the wearer's clothing facing the viewer and withportions of the diaper 20 partially cut away to show the underlyingfeatures. The illustrated diaper 20 defines a front waist region 22, aback waist region 24, a crotch region 26 that extends between andconnects the front and back waist regions 22 and 24, a longitudinaldirection or length dimension 38 and a lateral direction or widthdimension 40. As used herein, the term “longitudinal direction” meansthe direction that is parallel to the long dimension (usually machinedirection) of the diaper 20 and generally corresponds to the “y”direction of the diaper 20. As used herein the term “lateral direction”means the direction that coincides with the width direction whichgenerally is perpendicular to the longitudinal of machine direction ofthe diaper 20 and generally corresponds to the “x” direction of thediaper 20.

[0030] Measurements of the area immediately within the outer perimeteror outer periphery 46 of the diaper 20 along the longitudinal direction38 and the lateral direction 40 provide the area (Table 1) for theunfolded configuration or footprint of the diaper 20. The method ofmeasurement is discussed in detail below in Example 1A. The front waistregion 22 includes the portion of the diaper 20 which, when worn, ispositioned on the front of the wearer. The front waist region 22 furtherdefines front ear regions 72 generally in the laterally outward portionsof the front waist region 22. The back waist region 24 comprises theportion of the diaper 20 which, when worn, is positioned on the back ofthe wearer. The back waist region 24 further includes back ear portions70. When the diaper 20 is worn, back ear portions 70 are overlapped overfront ear regions 72, as shown in FIG. 2. The crotch region 26 of thediaper 20 includes the portion of the diaper 20 which, when worn, ispositioned between the legs of the wearer and covers the lower torso ofthe wearer.

[0031] The diaper 20 defines a pair of laterally opposed side edges 30,a pair of longitudinally opposed waist edges 32, an interior surface 34(facing away from the viewer) which is configured to contact the wearer,and an exterior surface 36, opposite the interior surface 34, which isconfigured to contact the wearer's clothing in use. The illustrateddiaper 20 also includes an outer cover 42 and a bodyside liner 44 whichis connected to the outer cover 42 in a superposed relationship and anabsorbent core 28. The absorbent core 28 is located between the outercover 42 and the bodyside liner 44. The laterally opposed side edges 30of the diaper 20 are generally defined by the side edges 30 of the outercover 42 which further define leg openings that are formed when thearticle is worn and may be curvilinear. The waist edges 32 of the diaper20 are generally defined by the waist edges 32 of the outer cover 42 anddefine a waist opening which is configured to encircle the waist of thewearer when worn. The absorbent core 28 is configured to contain and/orabsorb any body exudates discharged from the wearer. The diaper 20 mayfurther include leg elastics 54, containment flaps (not shown) and waistelastics 58 as are known to those skilled in the art. It should berecognized that individual components of the diaper 20 may be optionaldepending upon the intended use of the diaper 20.

[0032] The diaper 20 may be of various suitable shapes. For example, inthe unfastened configuration as illustrated in FIG. 1, the diaper 20 mayhave an overall rectangular shape, T-shape or a generally I-shape. Inthe embodiment shown in FIG. 1, the diaper 20 has an approximatelyhourglass shape in an unfastened configuration. Examples of diaperconfigurations suitable for use in connection with the instantapplication and other diaper components suitable for use on diapers aredescribed in U.S. Pat. No. 4,798,603 issued Jan. 17, 1989, to Meyer etal.; U.S. Pat. No. 5,176,668 issued Jan. 5, 1993, to Bernardin; U.S.Pat. No. 5,192,606 issued Mar. 9, 1993, to Proxmire et al., and U.S.Pat. No. 5,509,915 issued Apr. 23, 1996, to Hanson et al., thedisclosures of which are herein incorporated by reference.

[0033] The bodyside liner 44, as representatively illustrated in FIG. 1,suitably presents a bodyfacing surface which is compliant, soft feeling,and nonirritating to the wearer's skin. Further, the bodyside liner 44may be less hydrophilic than the absorbent core 28, to present arelatively dry surface to the wearer and to isolate the wearer's skinfrom liquids held in the absorbent core 28.

[0034] The absorbent core 28 of the diaper 20, as representativelyillustrated in FIG. 1, may suitably include a matrix of hydrophilicfibers, such as a web of cellulosic fluff, mixed with particles of ahigh-absorbency material commonly known as superabsorbent material(SAPs); in a particular aspect, the absorbent core 28 includes a matrixof cellulosic fluff such as wood pulp fluff and superabsorbenthydrogel-forming particles, namely, SAPs. The wood pulp fluff may beexchanged with synthetic, polymeric, meltblown fibers or with acombination of meltblown fibers and natural fibers. The SAPs may besubstantially homogeneously mixed with the hydrophilic fibers or may benonuniformly mixed. The fluff and SAPs may also be selectively placedinto desired zones of the absorbent core 28 to better contain and absorbbody exudates. The concentration of the SAPs may also vary through thethickness of the absorbent core 28. Alternatively, the absorbent core 28may include a laminate of fibrous webs and SAPs or other suitable meansof maintaining SAPs in a localized area.

[0035] The absorbent core 28 may have any of a number of shapes. Forexample, the absorbent core 28 may be rectangular, I-shaped (includingan hour glass shape, or a shape which is expanded outward at one or bothends), T-shaped, and so forth. It is generally preferred that theabsorbent core 28 be narrow in the crotch region 26 of the diaper 20.The size and the absorbent capacity of the absorbent core 28 should becompatible with the size of the intended wearer and the liquid loadingimparted by the intended use of the absorbent article.

[0036] The high absorbency material or particles, i.e., SAPs, may be inany of a wide variety of geometric forms. As a general rule, it ispreferred that the high absorbency material be in the form of discreteparticles, SAPs, which may take any of a number of shapes. The SAPs aregenerally present in the absorbent core 28 in an amount of from about 5to about 90 weight percent based on total weight of the absorbent core28. Desirably, the SAPs are present in the absorbent core 28 in anamount of from about 20 to about 90 weight percent based on the totalweight of the absorbent core 28. More desirably, the SAPs are present inthe absorbent core 28 in an amount of from about 30 to about 90 weightpercent based on the total weight of the absorbent core 28. Yet evenmore desirably, the SAPs are present in the absorbent core 28 in anamount of from about 40 to about 90 weight percent based on the totalweight of the absorbent core 28. SAPs are well known to those skilled inthe art and are widely commercially available.

[0037] A fastening system helps maintain the initial fastened positionof the diaper 20 during use so as to maintain proper tension andultimately proper fit. As illustrated in FIGS. 1 and 2, the diaper 20includes the back ear portion 70, which has fasteners 60. The fasteners60 may include an attachment portion 66, such as an adhesive, desirablya pressure sensitive adhesive. Alternatively, the attachment portion 66may include a hook material, and so forth. The front waist region 22includes a landing zone 80. If the attachment portion 66 of the fastener60 is an adhesive, the landing zone desirably includes a materialconfigured to receive and hold an adhesive fastener thereto.Alternatively, is the attachment portion 66 of the fastener 60 is a hookmaterial, the landing zone desirably includes a loop material forreleasably coupling the hook material thereto. In use, the caregiveroverlaps each back ear portion 70 and fastener 60 over the front waistregion 22 and engages the fasteners 60 to the landing zone 80, asillustrated in FIG. 2, creating an overlap region 104 which holds thediaper 20 in position about a torso.

[0038] The diaper 20 has been discussed in detail herein. However, itwill be understood by those skilled in the art that the foregoingdescription also applies to a training pant 200 (FIG. 12) and to anadult incontinence pant or garment, whether formed as a pant (not shown)or provided as a refastenable garment 300 (FIG. 13).

[0039] Turning now to folding configurations or “footprints”, adisposable absorbent article 10, that is, for purposes of illustrationonly and not by way of limitation, the diaper 20 illustrated in FIGS. 1and 2, is folded to provide a reduced or more compact configuration orfootprint. The various compact footprints, created by different foldingtechniques, are compared to the unfolded footprint, that is, themeasurement of the area as defined immediately within the outerperimeter or outer periphery 46 of the diaper 20, as described in detailin Example 1A, and the results are provided in Table 1. Each foldedcompact configuration of each article 10, namely, the diaper 20described below and shown in FIGS. 4-9 is measured along a longitudinaldirection or length dimension 138 (generally along a “y” direction) anda lateral direction or width dimension 140 (generally along an “x”direction).

[0040] In addition, a depth dimension 142 (generally along a “z”direction, generally positioned perpendicularly relative to a “y”direction), is measured in both the unfolded footprint of the diaper 20,and the folded compact footprint. The description of the measurement ofthe depth dimension will be described in the Examples, below. Therefore,area and volume calculations of each folded article compared to theunfolded article are provided in Table 1.

[0041] Folds in disposable absorbent articles containing highlyabsorbent materials have been problematic. Folds have created problemsin absorption in the folded area, and for this reason have traditionallybeen kept to a minimum. Folds cause compacting of the cellulosicmaterial in the inside of the folded “crease,” and tend to causemovement (stretching) of the absorbent materials on the outside of thefold toward either side of the fold. This results in a reduction in theabsorbent capabilities of both the cellulosic material and the highlyabsorbent materials in and around the folded area. Not to be constrainedto this explanation, one mechanism of this reduction of absorbentcapability is believed to be due to discontinuities in the absorbentcomposite caused by this stretching and compacting.

[0042] Folds in the present invention have been created which work withexisting folded patterns, in order to minimize the sharp angle ofadditional folds. It is believed that folds, such as those illustratedin FIGS. 6-8, which are created after the initial bifolding of thediaper 20, as shown in FIG. 4, have a larger radius of curvature, whichreduce or eliminate the disadvantages described previously for foldshaving a sharp angle or small radius of curvature. “Folds” or “foldedconfiguration” as used herein refers to at least one planar surfacefollowed by at least one radius of curvature.

[0043] In initially folding a disposable absorbent article 10 such as,by way of non-limiting example, a diaper 20, each side 148 is foldedinward, including the back ear portions 70 and the front ear regions 72,over the area containing the absorbent core 28, as shown in FIG. 3. Thediaper 20 is then folded again at approximately the center 144 toprovide a bifolded diaper 20 having two overlapping panels 150 ofapproximately equal length, as schematically illustrated in FIG. 4.

[0044] In an alternative, as schematically shown in FIG. 5, the diaper20, folded initially as shown in FIG. 3 is folded such that each end 152is folded over and overlaps about a third of the other to provide threeapproximately equal and overlapping panels 150. In this manner, atrifolded diaper 20 is provided.

[0045] In another alternative, as schematically illustrated in FIG. 6,the bifolded diaper 20 shown in FIG. 4 is then overlapped again toprovide a quadrifolded diaper 20 having four approximately equal andoverlapping panels 150.

[0046] In yet another alternative, as schematically illustrated in FIG.7, the bifolded diaper 20 shown in FIG. 4 is then folded such thatapproximately one third of each bifolded end 154 of the folded diaper isfolded over each side of a center portion to provide an “S” foldeddiaper having six approximately equal and overlapping panels 150.

[0047] In still yet another alternative, as schematically illustrated inFIG. 8, each end 154 of the bifolded diaper 20 shown in FIG. 4 isoverlapped inwardly, toward a center portion 156 to provide a “Pretzel”fold having eight overlapping panels 150.

[0048] In still a further embodiment, as illustrated in FIG. 9, thediaper 20 of FIG. 3 is rolled from one end to the other to form agenerally cylindrical shape. This configuration, providing a continuousrotation of the diaper 20 around a center, differs from folds; it has noplanar surface in the folded configuration, other than each end, sinceit forms, generally, a cylindrical shape. It will be understood,however, that the present article 10 may be folded in any mannerconsistent with the present invention, and the foregoing foldingtechniques and rolled technique are not intended to limit the scope ofthe invention.

[0049] It will also be understood that the article 10 is folded suchthat pressure to the absorbent material is impacted as little aspossible. That is, folds are placed longitudinally along either side ofthe crotch. Folds in the crotch area generally have a greater radius ofcurvature and are positioned in an area of the article 10, that is, thediaper 20 in this instance, which would naturally bend around the bodyof a wearer and/or to provide ease of unfolding by a caregiver. Scoringor embossing the portions of the article 10 along longitudinal foldlines and near the waist would prevent cracking, and provide somebarrier properties, which would be desirable especially at the waistarea. Rolling the article 10, as shown generally by the diaper 20 inFIG. 9 with the thinnest portion, that is, the outer cover 42 of thediaper 20 positioned toward the inside of the roll, increases the radiusof curvature of the thicker portion thus reducing the likelihood ofcracking.

[0050] In folding the article 10, folding the fasteners 60 must be takeninto consideration. Fasteners 60 desirably are not folded in the width40 (cross-machine) direction, because such folding impacts the abilityof the attachment portions 66 to fasten to the landing zone 80. Damageto the attachment portions 66 may occur if the fastener 60 is bent suchthat a portion of the fastener 60 lies in one plane while anotherportion lies in a curve and/or another plane. Specifically, theattachment portions 66 may be damaged such that they are not capable ofmaintaining a sufficient contact with the landing zone 80, therebycausing the article 10 to unfasten from a torso. Therefore, thefasteners 60 are desirably maintained in a consistent plane or planarsurface when folded with the article 10 in any of the foregoing foldedconfigurations so that the fastener 60 and attachment portion 66 thereofis lying substantially within the same plane.

[0051] The article 10 may be folded by hand, or it is desirably machinefolded (not shown). The article 10 is then packaged.

[0052] Schematically shown in FIG. 10 is one method and apparatus 157 ofpackaging an article. In this example, a first reel 158 has sheetmaterial 159 which is rotatably supported on a bed 160 having a vacuumcavity former 162 provided where the article 10 is disposed. Articles10, such as, for example, the diaper 20 folded as illustrated in FIG. 7,are provided at a loading station 164 and they are disposed on the sheetmaterial 159 over the cavity former 162. The articles 10 are carried toa packaging station 165 which has a vacuum chamber (not shown). Thepackaging station 165 also contains film (not shown) and a sealingapparatus (not shown) for sealing the articles 10 in the cavities whilethey are in the vacuum chamber. The articles 10 in the forming cavities162 are carried into the packaging station 165 and the chamber isclosed. A vacuum is applied to the articles 10 and the cavities 162, andfilm is then positioned and sealed over each cavity via sealing devices,such as thermal sealing, ultrasonic bonding, or any other sealingmethods known by those skilled in the art. The vacuum depressurizes thechamber in the packaging station to a pressure which is less than theatmospheric pressure outside of the chamber. After the package issealed, the vacuum is removed from the chamber, and the chamber and thearticles sealed in packages therein are permitted to return to regularatmospheric pressure, which results in compression of the articles inthe packages, providing a soft package (form-fill-seal) which is formedabout the article 10. The packaged article 190 may thereafter be removed(not shown).

[0053] It will be appreciated that many techniques and apparatus forvacuum packaging are known to those skilled in the art, and arecommercially available. Any type of packaging device may be utilizedwhich permits the article 10 to perform in the manner described andillustrated herein. Another type of vacuum packaging is disclosed, forexample, but not by way of limitation, in U.S. Pat. No. 4,833,862 toBortolani, et al., which is hereby incorporated by reference in itsentirety. Many techniques and apparatus for vacuum packaging are knownin the art and commercially available.

[0054] The amount of vacuum is an amount necessary to result incompression of the article so that it may be contained and reduced insize within and along with the package, but not so much as to disruptelements of the article, such as an amount which would displace the SAPsor overly compress the cellulosic material. The amount of vacuum isgenerally in a range of about 32 to about 5 inches of Mercury. Desirablythe range is about 30 to about 8 inches of Mercury. Even more desirably,the range is about 28 to about 10 inches of Mercury. Yet even moredesirably, the range is about 27 to about 15 inches of Mercury. Stillyet even more desirably, the range is about 26 to about 18 inches ofMercury. However, yet even more desirably, the range is about 25 toabout 20 inches of Mercury.

[0055] It has been discovered, however, with regard to the articles 10,namely, the diaper 20 illustrated in FIGS. 6-9, that when folded, ittends to spring back out of the desired folded configuration prior tobeing sealed in a package. That is, the article 10 tends to move or“spring back” out of its desired folded configuration, and return backto its previous configuration. To eliminate this problem, the cavity forthe package was sized slightly smaller, i.e., about 0.1 to about 0.5inches, than the length dimension 138 and/or the width dimension 140 ofthe folded diaper 20. This slight reduction in the cavity dimension actsto minimize the spring back so that the article 10 is retained in itsdesired configuration or footprint until sealed. Alternatively and/or inaddition to, a weight may be applied temporarily to the folded article10, to induce some “memory” of the desired configuration until sealed ina package. In another alternative, an adhesive may be applied to aportion(s) of the article 10 prior to folding, to assist in holding itin the desired folded configuration. A pressure sensitive adhesive maybe used, or a cohesive adhesive, such as, by way of non-limitingexample, latex, may be utilized. The adhesive may be applied in spots,strips, patterns, decorations, and so forth. Further, the adhesive maybe clear and colorless, and applied over a decoration(s) on the articleto “hide” the adhesive. In another alternative, the adhesive may becolored, and may be applied as part or all or a decoration(s) on thearticle. In yet another alternative, the article 10 may be folded intothe desired configuration and banded by one or more bands which extendabout the perimeter of the article 10.

[0056] In the embodiment of FIG. 10, the package is at least partially apreformed package. The compression or pressure on the article may beexerted at least partially by the package. Alternatively, the packagemay be formed around the article 10.

[0057] The article, desirably vacuum packaged, is sealed in a packagedesirably constructed of a material with a substantially low gaspermeability, including, but not limited to, a polymeric film, such as,by way of non-limiting example, a polyethylene terephthalate (PET), apolyvinyldichloride (PVDC), having an oxygen transmission of about lessthan 3.0 cc/100 in²/24 hours @ 73 degrees F. and 0 percent relativehumidity (RH). Multilayer films, each providing a different function,may be utilized. For example, one layer may have a heat sealableproperty, such as polypropylene or polyethylene, another layer mayprovide strength, such as polyester and/or nylon, and another layer mayprovide substantially reduced gas permeability, such as PET or PVDC.Also, films with reduced permeability to vapors (that is, films thathave substantially low gas permeability or are substantially gasimpermeable for a variety of applications) can themselves be composites,such as where one layer is a flexible polymer, such as polyurethane,polyethylene, ether polyurethane, or polypropylene, while another layeris coated on or coextruded and serves as a barrier layer. Barrier layerscan generally be viewed as substantially organic based or substantiallyinorganic based. For example, U.S. Pat. No. 3,442,686, herebyincorporated by reference herein, describes a film composite in whichsilicon oxide coatings are deposited on polymers to serve as a barrierlayer. This produces barrier coatings on even quite thin polymer filmsof oxygen transmission rate properties of about 0.2 cc/100 in²/day andsimilar water vapor transmission rate properties. However, it will beappreciated that any material having substantially low gas permeabilityor substantially gas impermeable material(s) known in the art may beused.

[0058] Desirably, with a substantially low gas permeable material and/orpackage, the gas permeability rate is less than about 5.0 cc/100 in²/24hours to about 0.05 cc/100 in²/24 hours. More desirably, the gaspermeability rate is less than 4.0 cc/100 in²/24 hours to about 0.07cc/100 in²/24 hours. Even more desirably, the gas permeability rate isless than about 3.0 cc/100 in²/24 hours to about 0.10 cc/100 in²/24hours. Even more desirably, the gas permeability rate is less than about2.0 cc/100 in²/24 hours to about 0.10 cc/100 in²/24 hours.

[0059] A number of different packages may be utilized which are suitablefor use with the present invention. Types of packages which areparticularly suitable include, but are not limited to form-fill-sealpackages, blister packages, injection molded packages (with and withoutliving hinges), heat sealed pouches, thermally formed trays with lids,and any suitable package known to those skilled in the art.

[0060] Packaging the article using a substantially gas impermeablematerial permits the moisture content to be maintained. Mostimportantly, the moisture content can be maintained at a relatively lowlevel when hydrogen bonding type materials, e.g., cellulose and SAPs arepresent, as they are in the articles referenced herein. That is,inhibiting an increase in moisture while maintaining the article in itsfolded, compact, compressed and packaged state eliminates detrimentalhydrogen bonding from taking place that would have occurred if themoisture level in the absorbent core was too high at the time thearticle was packaged or during packaging, or if the article was packagedin a package having one or more openings in it.

[0061] Before the articles are packaged, and when the articles arepackaged, it is desirable to maintain a lower moisture level. Highmoisture levels result in hydrogen bonding in the absorbent core of thearticle. Therefore, the articles are desirably maintained and packagedwith an absorbent core at a moisture level of less than 10%. Moredesirably, the articles are maintained and packaged with an absorbentcore at a moisture level of less than 5%. Even more desirably, thearticles are maintained and packaged with an absorbent core at amoisture level of less than 3%.

[0062] In addition, it is advantageous to control heat during foldingand packaging the article. The temperature of at least the absorbentcore is desirably kept below about 110 degrees C. Even more desirably,the temperature of at least the absorbent core is kept at below about 80degrees C. Yet even more desirably, the temperature of at least theabsorbent core is kept below about 50 degrees C. Still even moredesirably, the temperature of at least the absorbent core should be keptbelow about 24 degrees C.

[0063] In addition, it is noted that vacuum packaging assists inpreserving desired characteristics of the absorbent web materials,particularly crosslinked cellulosic curly fibers and even more sonon-crosslinked cellulosic fibers by maintaining their stiffness andresiliency. Vacuum packaging is advantageous by providing pressure whichis applied relatively uniformly to the article. Vacuum packaging, eventhough the article is folded, creates fewer hard, highly bonded areas ofthe absorbent core (for example, in the target area of the absorbentcore 28) will not be at a higher density than the low basis weight areas(for example, the back of the absorbent core 28 the article 10).

[0064] FIGS. 11A-11C illustrate several different packaged compactabsorbent articles 190. Package 192A illustrates a form-fill-sealpackage holding a compact absorbent article 190A (such as, for example,the article shown in FIG. 7), as also generally shown in FIG. 10.Package 192B, as shown by FIG. 11B, shows a blister package having aliving hinge and holding a compact absorbent article 190B (such as thearticle shown in FIG. 9). FIG. 11C illustrates an injection moldedpackage having a living hinge (not shown) which holds a compactabsorbent article 190C. Each package 192A, 192B, and 192C is intended,without limitation, to illustrate some of the possible embodiments ofpackages which are suitable for use with the present invention, however,it will be understood that any package known in the art may be used. Thepackages 190A-190C desirably include curvilinear corners, and eachdesirably provides size information (FIG. 11A) for the compact absorbentarticle contained therein, as well as one or more attractivedecorations, such as one or more letters, numbers, symbols, designsand/or patterns, an area to write a user's name and other information,and so forth. In addition, a wet sheet packet, a lotion pocket, achanging sheet, a disposal bag, one or more coupons, and so forth may beincluded on an inside of the package, as illustrated in 190C, or on anoutside of the package (not shown). Desirably, each package 190A-190Cwill open without any small pieces of the package tearing awayseparately, which is undesirable in the presence of small children andinfants. The packages may be provided such that a plurality of singlepackaged articles are releasably coupled together by, for example, butnot pay way of limitation, perforations, bands, adhesives, and so forth.

[0065] Further desirably, as illustrated in FIG. 11A, the package 192Awill have a pull tab 194. The pull tab 194 desirably extends beyond aperimeter 196 of the package 192A, so that it is easy to grasp between athumb and a finger by a caregiver, and permits easy opening of thepackage while maintaining the package 192 in one piece after beingopened, and after the article has been removed.

[0066] The pull tab 194 shown in FIG. 11A may be formed as a portion ofthe top material 197 of the package 192A, and is desirably, but not byway of limitation, not coterminus with the bottom material 198 of thepackage 192A to which the top material 192 is sealed. The pull tab 194may have pull indicia such as words, symbols, and so forth (for example,but not by way of limitation, “Pull Here” illustrated in FIG. 11A). Thepull tab 194 may be formed of a thicker material, or may be embossed orotherwise textured, and so forth, to provide easy grasping and pullingby a caregiver. The pull tab 194 may be formed in one or more corners ofthe package 192A, or one or more pull tabs 194 may be provided on anyportion(s) of the package 192A (not shown). Desirably, the edges of thepull tab 194 are curvilinear.

[0067] Ideally, the compact absorbent article 190, when packaged, willhave a configuration that permits it to be placed in a purse, a jacketpocket, a pants pocket, or a shirt pocket. Each type of pocket hassomewhat different dimensions, but generally, it is desirable to have anarticle 190, for example, a single packaged diaper, which has a widthdimension of less than 6 inches, a length dimension of less than 11inches, and a depth dimension of less than 1.75 inches. More desirably,the article 190 will have a width dimension 138 of less than 5 inches, alength dimension 140 of less than 5.5 inches, and a depth dimension ofless than 1.5 inches. Even more desirably, the article 190 will have awidth dimension of less than 4.6 inches, a length dimension of less than4.0 inches, and a depth dimension of less than 1.75 inches. Yet evenmore desirably, the article 190 will have a width dimension of less than4.6 inches, a length dimension of less than 3.8 inches, and a depthdimension of less than 1.3 inches. Such ranges described herein providea footprint, that is, an area, or projected area, as well as a volumefor the packaged compact absorbent article 190 so that it easily fitsinto a shirt pocket, a pants pocket, a jacket pocket, a small purse, andso forth, to provide ease in carrying and concealing the article 190.

[0068] The area or footprint of the folded compact absorbent article 190is compared to the unfolded and laid flat with unretracted elastics andextended to ungathered length configuration of the article 10 (asexemplified by the disposable diaper 20), is provided in Table 1. Table1 provides the area for the unfolded and laid flat article 10 positionedas described above, as well as the area for each different type offolded compact absorbent article 190. Desirably, the ratio between thefolded configuration and the unfolded configuration is less than 0.14.More desirably, the ratio between the folded configuration and theunfolded configuration is less than 0.13. Even more desirably, the ratiobetween the folded configuration and the unfolded configuration is lessthan 0.12. Yet even more desirably, the ratio between the foldedconfiguration and the unfolded configuration is less than 0.11. However,yet even more desirably, the ratio between the folded configuration andthe unfolded configuration is less than 0.10. Still yet even moredesirably, the ratio between the folded configuration and the unfoldedconfiguration is less than 0.09. Still yet even more desirably, theratio between the folded configuration and the unfolded configuration isless than 0.07. Yet even more desirably, the ratio between the foldedconfiguration and the unfolded configuration is less than 0.05.

[0069] The volume of the compact absorbent article is desirably lessthan 30 in³. More desirably, the volume of the compact absorbent articleis less than 15 in³. Even more desirably, the volume of the compactabsorbent article is less than 12 in³. yet even more desirably, thevolume of the compact absorbent article is less than 10 in ³. Still yeteven more desirably, the volume of the compact absorbent article is lessthan 7 in³. However, yet even more desirably, the volume of the compactabsorbent article is less than 5 in³.

[0070] When an article 10 is packaged, that is by way of non-limitingexample vacuum packaged, it is expected that its size will be reduced inwidth, length, and depth, i.e., in three dimensions. As measured in twodimensions, width and length (area-inches²) and compared against asubstantially similarly folded un-packaged article (Example 1 andExample 4D), the article 10 is desirably reduced in area by more thanabout 10 percent. Even more desirably, the article 10 is reduced in areaby more than about 12 percent. Yet even more desirably, the article 10is reduced in area by more than about 15 percent. Still yet even moredesirably, the article 10 is reduced in area by more than about 17percent. However, even more desirably, the article 10 is reduced in areaby more than about 20 percent. Yet even more desirably, the article 10is reduced in volume by more than about 22 percent.

[0071] When the article 10, as described immediately above is packagedand measured in three dimensions i.e., width, length and depth(volume-inches³) and compared against a substantially similarly foldedun-packaged article 10 (Example 1 and Example 4D), the article 10 isdesirably reduced in volume by more than about 10 percent. Even moredesirably, the article 10 is reduced in volume by more than about 15percent. Yet even more desirably, the article 10 is reduced in volume bymore than about 20 percent. Still yet even more desirably, the article10 is reduced in volume by more than about 30 percent. However, evenmore desirably, the article 10 is reduced in area by more than about 40percent. Yet even more desirably, the article 10 is reduced in volume bymore than about 45 percent. As described below in the TEST, this two andthree dimensional reduction (area and volume) resulted in no significantchanges in performance of the article.

EXAMPLES Example 1

[0072] A diaper (HUGGIES® ULTRATRIM® Step 3 diaper, available fromKimberly-Clark Corporation, Neenah, Wis.) was produced which is similarto the article illustrated in FIG. 1, and described in detail herein.The diaper was configured to fit an infant weighing about 16 to about 28pounds. The diaper was folded by hand as illustrated in FIG. 7 anddescribed previously in detail herein, in the “S” fold configuration,and positioned in a cavity formed from a material, namely, 611K—3 milnylon with LLDPE coextrusion, available from Curwood, New London, Wis.,having at least one layer of a substantially low gas permeability or onelayer of a substantially gas impermeable material, which was formed andpositioned in a horizontal form/fill/seal packaging machine, in thisinstance, a RapidPak RP-55, manufactured by Alkar-Rapidpak, Inc., Lodi,Wis. The top material, that is, the sealing cover, also having at leastone substantially gas impermeable layer, was a 48 gauge polyester filmwith 2 mils HDPE peel seal (coextrusion), available from Curwood, NewLondon, Wis. The top material was provided as a “peel back” material fora caregiver's convenience, and it was thermally sealed over the cavitywhile the cavity with the folded diaper therein was positioned in thevacuum chamber and a vacuum pressure in a range of about 20 to about 25inches of Mercury relative to the existing atmospheric pressure wasremoved from the chamber. The chamber was then returned to existingatmospheric pressure, which resulted in compression of the package andthe compact folded absorbent article therein. The packaged article wasthen removed from the chamber.

[0073] The dimensions of the S-folded diaper in its package were thencompared to the unfolded dimensions of the Step 3 diaper disclosed inExample 4, which was measured as described in detail in Example 1A. Thedimensions of the S-folded diaper in its package were then measured. Thewidth was 4.250 inches and the length was 2.500 inches. The area of theperimeter or “footprint” was 10.625 inches². The depth was 0.750 inches.The volume was 7.969 inches³. The ratio of the footprint of the S foldedvacuum packaged diaper compared to its unfolded footprint was 0.06. Themeasurement did not include any portion of the package which extendedbeyond the perimeter of the diaper, but only the diaper containedwithin. As compared to the S folded but un-packaged diaper of Example4D, the present vacuum packaging diaper only had about 78 percent of thearea of the unpackaged S folded diaper of Example 4D (an about 22percent reduction in area), and only had about 55 percent of the volumeof the unpackaged S folded diaper of Example 4D (an about 45 percentreduction in volume). TABLE 1 Diaper Dimensions HUGGIES ® ULTRATRIM ®DIMENSIONS PREEMIE (inches) AREA VOLUME (Examples 1A-1E) W L D (inches²)(inches³) *RATIO FLAT/UNFOLDED 99.59 BIFOLD (1A) 3.750 5.750 0.329 21.567.094 0.217 TRIFOLD (1B) 3.750 3.875 0.494 14.53 7.178 0.146 QUADRIFOLD(1C) 3.750 2.875 0.658 10.78 7.094 0.108 S-FOLD (1D) 3.750 2.000 0.9887.50 7.410 0.075 PRETZEL FOLD (1E) 3.750 1.500 1.317 5.63 7.408 0.056DIMENSIONS W L D AREA(in²) VOLUME(in³) *RATIO HUGGIES ® ULTRATRIM ® STEP1 (Examples 2A-2E) FLAT/UNFOLDED 128.61 BIFOLD (2A) 4.000 6.625 0.34326.50 9.100 0.206 TRIFOLD (2B) 4.000 4.375 0.514 17.50 9.000 0.136QUADRIFOLD (2C) 4.000 3.625 0.686 14.50 9.950 0.113 S-FOLD (2D) 4.0002.500 1.028 10.00 10.280 0.078 PRETZEL FOLD (2E) 4.000 1.750 1.317 7.009.219 0.054 HUGGIES ® ULTRATRIM ® STEP 2 (Examples 3A-3E) FLAT/UNFOLDED153.36 BIFOLD (3A) 4.125 7.500 0.350 30.94 10.828 0.202 TRIFOLD (3B)4.125 4.875 0.525 20.11 10.557 0.131 QUADRIFOLD (3C) 4.125 3.875 0.70015.94 11.189 0.104 S-FOLD (3D) 4.125 2.750 1.050 11.34 11.910 0.074PRETZEL FOLD (3E) 4.125 1.875 1.400 7.73 10.828 0.050 HUGGIES ®ULTRATRIM ® STEP 3 (Examples 4A-4E) FLAT/UNFOLDED 172.6 BIFOLD (4A)4.500 8.250 0.354 37.13 13.142 0.215 TRIFOLD (4B) 4.500 5.375 0.53124.19 12.844 0.140 QUADRIFOLD (4C) 4.500 4.000 0.708 18.00 12.744 0.104S-FOLD (4D) 4.500 3.000 1.063 13.50 14.351 0.078 PRETZEL FOLD (4E) 4.5001.875 1.417 8.44 11.956 0.049 HUGGIES ® ULTRATRIM ® STEP 4 (Examples5A-5E) FLAT/UNFOLDED 208.41 BIFOLD (5A) 4.0625 9.375 0.375 38.09 14.2820.183 TRIFOLD (5B) 4.0625 6.375 0.563 25.90 14.580 0.124 QUADRIFOLD (5C)4.0625 4.625 0.750 18.79 14.091 0.090 S-FOLD (5D) 4.0625 3.375 1.12513.71 14.425 0.066 PRETZEL FOLD (5E) 4.0625 2.250 1.500 9.14 13.7110.044 TABLE 1 (Continued) HUGGIES ® ULTRATRIM ® STEP 5 (Examples 6A-6E)FLAT/UNFOLDED 231.59 BIFOLD (6A) 4.375 9.625 0.383 42.11 16.128 0.182TRIFOLD (6B) 4.375 6.125 0.575 26.80 15.408 0.116 QUADRIFOLD (6C) 4.3754.750 0.767 20.78 15.939 0.090 S-FOLD (6D) 4.375 3.250 1.150 14.2216.352 0.061 PRETZEL FOLD (6E) 4.375 2.375 1.534 10.39 15.939 0.045HUGGIES ® ULTRATRIM ® STEP 6 (Examples 7A-7E) FLAT/UNFOLDED 265.52BIFOLD (7A) 4.500 10.375 0.399 46.69 18.628 0.176 TRIFOLD (7B) 4.5006.000 0.599 27.00 16.173 0.102 QUADRIFOLD (7C) 4.500 5.250 0.798 23.6318.853 0.089 S-FOLD (7D) 4.500 3.750 1.197 16.88 20.199 0.064 PRETZELFOLD (7E) 4.500 2.500 1.596 11.25 17.955 0.042

Example 1A

[0074] A diaper (HUGGIES® ULTRATRIM® diaper, available fromKimberly-Clark Corporation, Neenah, Wis.) was produced which is similarto the article illustrated in FIG. 1, and described in detail herein.The diaper was a “preemie” size, configured to fit a premature infant.The diaper was positioned in its unfolded configuration, e.g., it's laidflat with unretracted elastics and extended to ungathered lengthconfiguration, and, as disclosed in Table 1, the diaper was measured tohave an area or “footprint” of 99.59 inches². The area was determined asdescribed below.

[0075] A rectangular sheet of translucent paper large enough to coverthe absorbent article was obtained and utilized. The length and width ofthe sheet was measured to the nearest 0.01 inch. The paper was thenweighed to the nearest 0.001 gram. The weight measurement was divided bythe area measurement to determine the basis weight of the paper. Thearticle, in this instance, the diaper, was opened completely, includingany fasteners, and positioned in the laid flat configuration describedabove, on a planar surface. The article was taped to the surface usingmasking tape. For other disposable absorbent articles, such as trainingpants and adult incontinence pants, the articles were cut on each sidebetween the leg openings and the waist opening prior to being positionedand taped to the planar surface. The sheet was positioned over and uponthe disposable absorbent article, and a tracing of the outer perimeter,including fasteners, was made on the sheet. The paper was then cut alongthe traced line and weighed. The weight of the paper was multiplied bythe inverse of the basis weight obtained previously. The result was anestimate of the total square inches of the absorbent article, which wasreported to the nearest 0.01 in².

[0076] The diaper was then folded into the bifolded configurationillustrated in FIG. 4 by hand. The dimensions of the bifolded diaperwere then measured. That is, the diaper was positioned on a planarsurface and restrained by hand, if necessary, in the folded position,while the length measurement 138 and the width measurement 140 wereobtained and recorded.

[0077] The depth measurement 142 was obtained by measuring a standardpackaged bag of articles, that is, in this instance, a bag containingbifolded diapers. The height of the bag was divided by the total numberof panels (for example, in a bag of 24 bifolded diapers, there are 48panels; diapers in the bag were packaged in the bag horizontallyrelative to the top height of the bag). These numbers were recorded. Allmeasurements relating to diapers are in Tables 1 and 4.

[0078] As disclosed in Table 1, the width was 3.750 inches and thelength was 5.750 inches. The area or “footprint” was 21.56 inches². Thecalculated depth was 0.329 inches². The volume was 7.094 inches³. Theratio of the footprint of the bifolded diaper compared to its unfoldedfootprint was 0.217.

Example 1B

[0079] A diaper (HUGGIES® ULTRATRIM®) was produced which is similar tothe article illustrated in FIG. 1, and described in detail herein. Thediaper was a “preemie”, configured to fit a premature infant. The diaperwas positioned in its completely unfolded configuration, as described inExample 1A. As disclosed in Table 1, the diaper was measured to have anarea or “footprint” of 99.59 inches². The diaper was folded into thetrifolded configuration illustrated in FIG. 5 by hand, and was measuredin the same manner as described in Example 1A.

[0080] As disclosed in Table 1, the width was 3.750 inches and thelength was 3.875 inches. The area or “footprint” was 14.53 inches². Thecalculated depth was 0.494 inches. The volume was 7.178 inches³. Theratio of the footprint of the trifolded diaper compared to its unfoldedfootprint was 0.146.

Example 1C

[0081] A diaper (HUGGIES® ULTRATRIM®) was produced which is similar tothe article illustrated in FIG. 1, and described in detail herein. Thediaper was a “preemie” size, configured for a premature infant. Thediaper was positioned in its completely unfolded configuration, asdescribed in Example 1A. As disclosed in Table 1, the diaper wasmeasured to have an area or “footprint” of 99.592 inches. The diaper wasfolded into the quadrifolded configuration illustrated in FIG. 6 byhand, and was measured in the same manner as described in Example 1A.

[0082] As disclosed in Table 1, the width was 3.750 inches and thelength was 2.875 inches. The area or “footprint” was 10.78 inches². Thecalculated depth was 0.658 inches. The volume was 7.094 inches³. Theratio of the footprint of the quadrifolded diaper compared to itsunfolded footprint was 0.108.

Example 1D

[0083] A diaper (HUGGIES® ULTRATRIM®) was produced which is similar tothe article illustrated in FIG. 1, and described in detail herein. Thediaper was a “preemie” size, configured for a premature infant. Thediaper was positioned in its completely unfolded configuration, and asdisclosed in Example 1A. As disclosed in Table 1, the diaper wasmeasured to have an area or “footprint” of 99.59 inches². The diaper wasfolded into the “S” folded configuration illustrated in FIG. 7 by hand,and was measured in the same manner as described in Example 1A.

[0084] As disclosed in Table 1, the width was 3.75 inches and the lengthwas 2.000 inches. The area or “footprint” was 7.50 inches². Thecalculated depth was 0.988 inches. The volume was 7.410 inches³. Theratio of the footprint of the “S” folded diaper compared to its unfoldedfootprint was 0.075.

Example 1E

[0085] A diaper (HUGGIES® ULTRATRIM®) was produced which is similar tothe article illustrated in FIG. 1, and described in detail herein. Thediaper was a “preemie” size, configured for a premature infant. Thediaper was positioned in its completely unfolded configuration, asdescribed in Example 1A. As disclosed in Table 1, the diaper wasmeasured to have an area or “footprint” of 99.59² inches. The diaper wasfolded into the “Pretzel” folded configuration illustrated in FIG. 8 byhand, and was measured in the same manner as described in Example 1A.

[0086] As disclosed in Table 1, the width was 3.750 inches and thelength was 1.500 inches. The area or “footprint” was 5.63 inches². Thecalculated depth was 1.317 inches. The volume was 7.408 inches³. Theratio of the footprint of the “Pretzel” folded diaper compared to itsunfolded footprint was 0.056.

Example 2A

[0087] A diaper (HUGGIES® ULTRATRIM®) was produced which is similar tothe article illustrated in FIG. 1, and described in detail herein. Thediaper was a “Step 1” size, configured to fit an infant having a weightof about 8 lbs. to about 14 lbs. The diaper was positioned in itscompletely unfolded configuration, as described in Example 1A. Asdisclosed in Table 1, the diaper was measured to have an area or“footprint” of 128.61 inches². The diaper was folded into the bifoldedconfiguration illustrated in FIG. 4 by hand, and it was measured in thesame manner as described in Example 1A.

[0088] As disclosed in Table 1, the width was 4.000 inches and thelength was 6.625 inches. The area or “footprint” was 26.50 inches². Thecalculated depth was 0.343 inches. The volume was 9.100 inches³. Theratio of the footprint of the bifolded diaper compared to its unfoldedfootprint was 0.206.

Example 2B

[0089] A diaper (HUGGIES® ULTRATRIM®) was produced which is similar tothe article illustrated in FIG. 1, and described in detail herein. Thediaper was a “Step 1” size, configured to fit an infant having a weightof about 8 lbs. to about 14 lbs. The diaper was positioned in itscompletely unfolded configuration, as described in Example 1A. Asdisclosed in Table 1, the diaper was measured to have an area or“footprint” of 128.61 inches². The diaper was folded into the trifoldedconfiguration illustrated in FIG. 5 by hand, and it was measured in thesame manner as described in Example 1A.

[0090] As disclosed in Table 1, the width was 4.000 inches and thelength was 4.375 inches. The area or “footprint” was 17.50 inches². Thecalculated depth was 0.514 inches. The volume was 9.000 inches³. Theratio of the footprint of the trifolded diaper compared to its unfoldedfootprint was 0.136.

Example 2C

[0091] A diaper (HUGGIES® ULTRATRIM®) was produced which is similar tothe article illustrated in FIG. 1, and described in detail herein. Thediaper was a “Step 1” size, configured to fit an infant having a weightof about 8 lbs. to about 14 lbs. The diaper was positioned in itscompletely unfolded configuration, as described in Example 1A. Asdisclosed in Table 1, the diaper was measured to have an area or“footprint” of 128.61 inches². The diaper was folded into thequadrifolded configuration illustrated in FIG. 6 by hand, and it wasmeasured in the same manner as described in Example 1A.

[0092] As disclosed in Table 1, the width was 4.000 inches and thelength was 3.625 inches. The area or “footprint” was 14.50 inches². Thecalculated depth was 0.686 inches. The volume was 9.950 inches³. Theratio of the footprint of the quadrifolded diaper compared to itsunfolded footprint was 0.113.

Example 2D

[0093] A diaper (HUGGIES® ULTRATRIM®) was produced which is similar tothe article illustrated in FIG. 1, and described in detail herein. Thediaper was a “Step 1” size, configured to fit an infant having a weightof about 8 lbs. to about 14 lbs. The diaper was positioned in itscompletely unfolded configuration, described in Example 1A. As disclosedin Table 1, the diaper was measured to have an area or “footprint” of128.61 inches². The diaper was folded into the “S” folded configurationillustrated in FIG. 7 by hand, and it was measured in the same manner asdescribed in Example 1A.

[0094] As disclosed in Table 1, the width was 4.000 inches and thelength was 2.500 inches. The area or “footprint” was 10.000 inches². Thecalculated depth was 1.028 inches. The volume was 10.280³. The ratio ofthe footprint of the “S” folded diaper compared to its unfoldedfootprint was 0.078.

Example 2E

[0095] A diaper (HUGGIES® ULTRATRIM®) was produced which is similar tothe article illustrated in FIG. 1, and described in detail herein. Thediaper was a “Step 1” size, configured to fit an infant having a weightof about 8 lbs. to about 14 lbs. The diaper was positioned in itscompletely unfolded configuration, as described in Example 1A. Asdisclosed in Table 1, the diaper was measured to have an area or“footprint” of 128.61 inches². The diaper was folded into the “Pretzel”folded configuration illustrated in FIG. 8 by hand, and it was measuredin the same manner as described in Example 1A.

[0096] As disclosed in Table 1, the width was 4.000 inches and thelength was 1.750 inches. The area or “footprint” was 7.00 inches². Thecalculated depth was 1.317 inches. The volume was 9.219 inches³. Theratio of the footprint of the “Pretzel” folded diaper compared to itsunfolded footprint was 0.054.

Example 3A

[0097] A diaper (HUGGIES® ULTRATRIM®) was produced which is similar tothe article illustrated in FIG. 1, and described in detail herein. Thediaper was a “Step 2” size, configured to fit an infant having a weightof about 12 lbs. to about 18 lbs. The diaper was positioned in itscompletely unfolded configuration, as described in Example 1A. Asdisclosed in Table 1, the diaper was measured to have an area or“footprint” of 153.36 inches². The diaper was folded into the bifoldedconfiguration illustrated in FIG. 4 by hand, and it was measured in thesame manner as described in Example 1A.

[0098] As disclosed in Table 1, the width was 4.125 inches and thelength was 7.500 inches. The area or “footprint” was 30.94 inches². Thecalculated depth was 0.350 inches. The volume was 10.828 inches³. Theratio of the footprint of the bifolded diaper compared to its unfoldedfootprint was 0.202.

Example 3B

[0099] A diaper (HUGGIES® ULTRATRIM®) was produced which is similar tothe article illustrated in FIG. 1, and described in detail herein. Thediaper was a “Step 2” size, configured to fit an infant having a weightof about 12 lbs. to about 18 lbs. The diaper was positioned in itscompletely unfolded configuration, as described in Example 1A. Asdisclosed in Table 1, the diaper was measured to have an area or“footprint” of 153.36 inches². The diaper was folded into the trifoldedconfiguration illustrated in FIG. 5 by hand, and it was measured in thesame manner as described in Example 1A.

[0100] As disclosed in Table 1, the width was 4.125 inches and thelength was 4.875 inches. The area of the perimeter or “footprint” was20.11 inches². The calculated depth was 0.525 inches. The volume was10.557 inches³. The ratio of the footprint of the trifolded diapercompared to its unfolded footprint was 0.131.

Example 3C

[0101] A diaper (HUGGIES® ULTRATRIM®) was produced which is similar tothe article illustrated in FIG. 1, and described in detail herein. Thediaper was a “Step 2” size, configured to fit an infant having a weightof about 12 lbs. to about 18 lbs. The diaper was positioned in itsunfolded configuration, as described in Example 1A. As disclosed inTable 1, the diaper was measured to have an area or “footprint” of153.36 inches². The diaper was folded into the quadrifoldedconfiguration illustrated in FIG. 6 by hand, and it was measured in thesame manner as described in Example 1A.

[0102] As disclosed in Table 1, the width was 4.125 inches and thelength was 3.875 inches. The area or “footprint” was 15.94 inches². Thecalculated depth was 0.700 inches. The volume was 11.189 inches³. Theratio of the footprint of the quadrifolded diaper compared to itsunfolded footprint was 0.104.

Example 3D

[0103] A diaper (HUGGIES® ULTRATRIM®) was produced which is similar tothe article illustrated in FIG. 1, and described in detail herein. Thediaper was a “Step 2” size, configured to fit an infant having a weightof about 12 lbs. to about 18 lbs. The diaper was positioned in itscompletely unfolded configuration, as described in Example 1A. Asdisclosed in Table 1, the diaper was measured to have an area or“footprint” of 153.36 inches². The diaper was folded into the “S” foldedconfiguration illustrated in FIG. 7 by hand, and it was measured in thesame manner as described in Example 1A.

[0104] As disclosed in Table 1, the width was 4.125 inches and thelength was 2.750 inches. The area or “footprint” was 11.34 inches². Thecalculated depth was 1.050 inches. The volume was 11.910 inches³. Theratio of the footprint of the “S” folded diaper compared to its unfoldedfootprint was 0.074.

Example 3E

[0105] A diaper (HUGGIES® ULTRATRIM®) was produced which is similar tothe article illustrated in FIG. 1, and described in detail herein. Thediaper was a “Step 2” size, configured to fit an infant having a weightof about 12 lbs. to about 18 lbs. The diaper was positioned in itscompletely unfolded configuration, as described in Example 1A. Asdisclosed in Table 1, the diaper was measured to have an area or“footprint” of 153.36 inches². The diaper was folded into the “Pretzel”folded configuration illustrated in FIG. 8 by hand, and it was measuredin the same manner as described in Example 1A.

[0106] As disclosed in Table 1, the width was 4.125 inches and thelength was 1.875 inches. The area or “footprint” was 7.73 inches². Thecalculated depth was 1.400 inches. The volume was 10.828 inches³. Theratio of the footprint of the “Pretzel” folded diaper compared to itsunfolded footprint was 0.050.

Example 4A

[0107] A diaper (HUGGIES® ULTRATRIM®) was produced which is similar tothe article illustrated in FIG. 1, and described in detail herein. Thediaper was a “Step 3” size, configured to fit an infant having a weightof about 16 lbs. to about 28 lbs. The diaper was positioned in itscompletely unfolded configuration, as described in Example 1A. Asdisclosed in Table 1, the diaper was measured to have an area or“footprint” of 172.6 inches². The diaper was folded into the bifoldedconfiguration illustrated in FIG. 4 by hand, and it was measured in thesame manner as described in Example 1A.

[0108] As disclosed in Table 1, the width was 4.500 inches and thelength was 8.250 inches. The area or “footprint” was 37.13 inches². Thecalculated depth was 0.354 inches. The volume was 13.142 inches³. Theratio of the footprint of the bifolded diaper compared to its unfoldedfootprint was 0.215.

Example 4B

[0109] A diaper (HUGGIES® ULTRATRIM®) was produced which is similar tothe article illustrated in FIG. 1, and described in detail herein. Thediaper was a “Step 3” size, configured to fit an infant having a weightof about 16 lbs. to about 28 lbs. The diaper was positioned in itscompletely unfolded configuration, as described in Example 1A. Asdisclosed in Table 1, the diaper was measured to have an area or“footprint” of 172.6 inches². The diaper was folded into the trifoldedconfiguration illustrated in FIG. 5 by hand, and it was measured in thesame manner as described in Example 1A.

[0110] As disclosed in Table 1, the width was 4.500 inches and thelength was 5.375 inches. The area or “footprint” was 24.19 inches². Thecalculated depth was 0.531 inches. The volume was 12.844 inches³. Theratio of the footprint of the trifolded diaper compared to its unfoldedfootprint was 0.140.

Example 4C

[0111] A diaper (HUGGIES® ULTRATRIM®) was produced which is similar tothe article illustrated in FIG. 1, and described in detail herein. Thediaper was a “Step 3” size, configured to fit an infant having a weightof about 16 lbs. to about 28 lbs. The diaper was positioned in itscompletely unfolded configuration, as described in Example 1A. Asdisclosed in Table 1, the diaper was measured to have an area or“footprint” of 172.6 inches². The diaper was folded into thequadrifolded configuration illustrated in FIG. 6 by hand, and it wasmeasured in the same manner as described in Example 1A.

[0112] As disclosed in Table 1, the width was 4.500 inches and thelength was 4.000 inches. The area or “footprint” was 18.0 inches². Thedepth was 0.708 inches. The volume was 12.744 inches³. The ratio of thefootprint of the quadrifolded diaper compared to its unfolded footprintwas 0.104.

Example 4D

[0113] A diaper (HUGGIES® ULTRATRIM®) was produced which is similar tothe article illustrated in FIG. 1, and described in detail herein. Thediaper was a “Step 3” size, configured to fit an infant having a weightof about 16 lbs. to about 28 lbs. The diaper was positioned in itscompletely unfolded configuration, as described in Example 1A. Asdisclosed in Table 1, the diaper was measured to have an area or“footprint” of 172.6 inches². The diaper was folded into the “S” foldedconfiguration illustrated in FIG. 7 by hand, and it was measured in thesame manner as described in Example 1A.

[0114] As disclosed in Table 1, the width was 4.500 inches and thelength was 3.000 inches. The area or “footprint” was 13.50 inches². Thecalculated depth was 1.063 inches. The volume was 14.351 inches³. Theratio of the footprint of the “S” folded diaper compared to its unfoldedfootprint was 0.078.

Example 4E

[0115] A diaper (HUGGIES® ULTRATRIM®) was produced which is similar tothe article illustrated in FIG. 1, and described in detail herein. Thediaper was a “Step 3” size, configured to fit an infant having a weightof about 16 lbs. to about 28 lbs. The diaper was positioned in itscompletely unfolded configuration, as described in Example 1A. Asdisclosed in Table 1, the diaper was measured to have an area or“footprint” of 172.6 inches². The diaper was folded into the “Pretzel”folded configuration illustrated in FIG. 8 by hand, and it was measuredin the same manner as described in Example 1A.

[0116] As disclosed in Table 1, the width was 4.500 inches and thelength was 1.875 inches. The area or “footprint” was 8.44 inches². Thecalculated depth was 1.417 inches. The volume was 11.956 inches³. Theratio of the footprint of the “Pretzel” folded diaper compared to itsunfolded footprint was 0.049.

Example 5A

[0117] A diaper (HUGGIES® ULTRATRIM®) was produced which is similar tothe article illustrated in FIG. 1, and described in detail herein. Thediaper was a “Step 4” size, configured to fit an infant having a weightof about 22 lbs. to about 37 lbs. The diaper was positioned in itscompletely unfolded configuration, as described in Example 1A. Asdisclosed in Table 1, the diaper was measured to have an area or“footprint” of 208.41 inches². The diaper was folded into the bifoldedconfiguration illustrated in FIG. 4 by hand, and it was measured in thesame manner as described in Example 1A.

[0118] As disclosed in Table 1, the width was 4.0625 inches and thelength was 9.375 inches. The area or “footprint” was 38.09 inches². Thecalculated depth was 0.375 inches. The volume was 14.282 inches³. Theratio of the footprint of the bifolded diaper compared to its unfoldedfootprint was 0.183.

Example 5B

[0119] A diaper (HUGGIES® ULTRATRIM®) was produced which is similar tothe article illustrated in FIG. 1, and described in detail herein. Thediaper was a “Step 4” size, configured to fit an infant having a weightof about 22 lbs. to about 37 lbs. The diaper was positioned in itscompletely unfolded configuration, as described in Example 1A. Asdisclosed in Table 1, the diaper was measured to have an area or“footprint” of 208.41 inches². The diaper was folded into the trifoldedconfiguration illustrated in FIG. 5 by hand, and it was measured in thesame manner as described in Example 1A.

[0120] As disclosed in Table 1, the width was 4.0625 inches and thelength was 6.375 inches. The area or “footprint” was 25.90 inches². Thecalculated depth was 0.563 inches. The volume was 14.580 inches³. Theratio of the footprint of the trifolded diaper compared to its unfoldedfootprint was 0.124.

Example 5C

[0121] A diaper (HUGGIES® ULTRATRIM®) was produced which is similar tothe article illustrated in FIG. 1, and described in detail herein. Thediaper was a “Step 4” size, configured to fit an infant having a weightof about 22 lbs. to about 37 lbs. The diaper was positioned in itscompletely unfolded configuration, as described in Example 1A. Asdisclosed in Table 1, the diaper was measured to have an area or“footprint” of 208.41 inches². The diaper was folded into thequadrifolded configuration illustrated in FIG. 6 by hand, and it wasmeasured in the same manner as described in Example 1A.

[0122] As disclosed in Table 1, the width was 4.0625 inches and thelength was 4.625 inches. The area or “footprint” was 18.79 inches². Thecalculated depth was 0.750 inches. The volume was 14.091 inches³. Theratio of the footprint of the quadrifolded diaper compared to itsunfolded footprint was 0.090.

Example 5D

[0123] A diaper (HUGGIES® ULTRATRIM®) was produced which is similar tothe article illustrated in FIG. 1, and described in detail herein. Thediaper was a “Step 4” size, configured to fit an infant having a weightof about 22 lbs. to about 37 lbs. The diaper was positioned in itscompletely unfolded configuration, as described in Example 1A. Asdisclosed in Table 1, the diaper was measured to have an area or“footprint” of 208.41 inches². The diaper was folded into the “S” foldedconfiguration illustrated in FIG. 7 by hand, and it was measured in thesame manner as described in Example 1A.

[0124] As disclosed in Table 1, the width was 4.0625 inches and thelength was 3.375 inches. The area or “footprint” was 13.71 inches². Thecalculated depth was 1.125 inches. The volume was 14.425 inches³. Theratio of the footprint of the “S” folded diaper compared to its unfoldedfootprint was 0.066.

Example 5E

[0125] A diaper (HUGGIES® ULTRATRIM®) was produced which is similar tothe article illustrated in FIG. 1, and described in detail herein. Thediaper was a “Step 4” size, configured to fit an infant having a weightof about 22 lbs. to about 37 lbs. The diaper was positioned in itscompletely unfolded configuration, as described in Example 1A. Asdisclosed in Table 1, the diaper was measured to have an area or“footprint” of 208.41 inches². The diaper was folded into the “Pretzel”folded configuration illustrated in FIG. 8 by hand, and it was measuredin the same manner as described in Example 1A.

[0126] As disclosed in Table 1, the width was 4.0625 inches and thelength was 2.250 inches. The area or “footprint” was 9.14 inches². Thecalculated depth was 1.500 inches. The volume was 13.711 inches³. Theratio of the footprint of the “Pretzel” folded diaper compared to itsunfolded footprint was 0.044.

Example 6A

[0127] A diaper (HUGGIES® ULTRATRIM®) was produced which is similar tothe article illustrated in FIG. 1, and described in detail herein. Thediaper was a “Step 5” size, configured to fit an infant having a weightof over 27 lbs. The diaper was positioned in its completely unfoldedconfiguration, as described in Example 1A. As disclosed in Table 1, thediaper was measured to have an area or “footprint” of 231.59 inches².The diaper was folded into the bifolded configuration illustrated inFIG. 4 by hand, and it was measured in the same manner as described inExample 1A.

[0128] As disclosed in Table 1, the width was 4.375 inches and thelength was 9.625 inches. The area or “footprint” was 42.11 inches². Thecalculated depth was 0.383 inches. The volume was 16.128 inches³. Theratio of the footprint of the bifolded diaper compared to its unfoldedfootprint was 0.182.

Example 6B

[0129] A diaper (HUGGIES® ULTRATRIM®) was produced which is similar tothe article illustrated in FIG. 1, and described in detail herein. Thediaper was a “Step 5” size, configured to fit an infant having a weightof over 27 lbs. The diaper was positioned in its completely unfoldedconfiguration, as described in Example 1A. As disclosed in Table 1, thediaper was measured to have an area or “footprint” of 231.59 inches².The diaper was folded into the trifolded configuration illustrated inFIG. 5 by hand, and it was measured in the same manner as described inExample 1A.

[0130] As disclosed in Table 1, the width was 4.375 inches and thelength was 6.125 inches. The area or “footprint” was 26.80 inches². Thecalculated depth was 0.575. The volume was 15.408 inches³. The ratio ofthe footprint of the trifolded diaper compared to its unfolded footprintwas 0.116.

Example 6C

[0131] A diaper (HUGGIES® ULTRATRIM®) was produced which is similar tothe article illustrated in FIG. 1, and described in detail herein. Thediaper was a “Step 5” size, configured to fit an infant having a weightof over 27 lbs. The diaper was positioned in its completely unfoldedconfiguration, as described in Example 1A. As disclosed in Table 1, thediaper was measured to have an area or “footprint” of 231.59 inches².The diaper was folded into the quadrifolded configuration illustrated inFIG. 6 by hand, and it was measured in the same manner as described inExample 1A.

[0132] As disclosed in Table 1, the width was 4.375 inches and thelength was 4.750 inches. The area or “footprint” was 20.78 inches². Thecalculated depth was 0.767 inches. The volume was 15.939 inches³. Theratio of the footprint of the quadrifolded diaper compared to itsunfolded footprint was 0.090.

Example 6D

[0133] A diaper (HUGGIES® ULTRATRIM®) was produced which is similar tothe article illustrated in FIG. 1, and described in detail herein. Thediaper was a “Step 5” size, configured to fit an infant having a weightof over 27 lbs. The diaper was positioned in its completely unfoldedconfiguration, as described in Example 1A. As disclosed in Table 1, thediaper was measured to have an area or “footprint” of 231.59 inches².The diaper was folded into the “S” folded configuration illustrated inFIG. 7 by hand, and it was measured in the same manner as described inExample 1A.

[0134] As disclosed in Table 1, the width was 4.375 inches and thelength was 3.250 inches. The area of the perimeter or “footprint” was14.22 inches². The calculated depth was 1.150 inches. The volume was16.352 inches³. The ratio of the footprint of the “S” folded diapercompared to its unfolded footprint was 0.061.

Example 6E

[0135] A diaper (HUGGIES® ULTRATRIM®) was produced which is similar tothe article illustrated in FIG. 1, and described in detail herein. Thediaper was a “Step 5” size, configured to fit an infant having a weightof over 27 lbs. The diaper was positioned in its completely unfoldedconfiguration, as described in Example 1A. As disclosed in Table 1, thediaper was measured to have an area or “footprint” of 231.59 inches².The diaper was folded into the “Pretzel” folded configurationillustrated in FIG. 8 by hand, and it was measured in the same manner asdescribed in Example 1A.

[0136] As disclosed in Table 1, the width was 4.375 inches and thelength was 2.375 inches. The area or “footprint” was 10.39 inches². Thecalculated depth was 1.534 inches. The volume was 15.939 inches³. Theratio of the footprint of the “Pretzel” folded diaper compared to itsunfolded footprint was 0.045.

Example 7A

[0137] A diaper (HUGGIES® ULTRATRIM®) was produced which is similar tothe article illustrated in FIG. 1, and described in detail herein. Thediaper was a “Step 6” size, configured to fit an infant having a weightof over 35 lbs. The diaper was positioned in its completely unfoldedconfiguration, as described in Example 1A. As disclosed in Table 1, thediaper was measured to have an area or “footprint” of 265.52 inches².The diaper was folded into the bifolded configuration illustrated inFIG. 4 by hand, and it was measured in the same manner as described inExample 1A.

[0138] As disclosed in Table 1, the width was 4.500 inches and thelength was 10.375 inches. The area or “footprint” was 46.69 inches². Thecalculated depth was 0.399 inches. The volume was 18.628 inches³. Theratio of the footprint of the bifolded diaper compared to its unfoldedfootprint was 0.176.

Example 7B

[0139] A diaper (HUGGIES® ULTRATRIM®) was produced which is similar tothe article illustrated in FIG. 1, and described in detail herein. Thediaper was a “Step 6” size, configured to fit an infant having a weightof over 35 lbs. The diaper was laid flat in its completely unfoldedconfiguration, and, as disclosed in Table 1, the diaper was measured tohave an area or “footprint” of 265.52 inches². The diaper was foldedinto the trifolded configuration illustrated in FIG. 5 by hand, and itwas measured in the same manner as described in Example 1A.

[0140] As disclosed in Table 1, the width was 4.5 inches and the lengthwas 6.00 inches. The area or “footprint” was 27.00 inches². Thecalculated depth was 0.599 inches. The volume was 16.173 inches³. Theratio of the footprint of the trifolded diaper compared to its unfoldedfootprint was 0.102.

Example 7C

[0141] A diaper (HUGGIES® ULTRATRIM®) was produced which is similar tothe article illustrated in FIG. 1, and described in detail herein. Thediaper was a “Step 6” size, configured to fit an infant having a weightof over 35 lbs. The diaper was positioned in its completely unfoldedconfiguration, as described in Example 1A. As disclosed in Table 1, thediaper was measured to have an area or “footprint” of 265.52 inches².The diaper was folded into the quadrifolded configuration illustrated inFIG. 6 by hand, and it was measured in the same manner as described inExample 1A.

[0142] As disclosed in Table 1, the width was 4.500 inches and thelength was 5.250 inches. The area or “footprint” was 23.63 inches². Thecalculated depth was 0.798 inches. The volume was 18.853 inches³. Theratio of the footprint of the quadrifolded diaper compared to itsunfolded footprint was 0.089.

Example 7D

[0143] A diaper (HUGGIES® ULTRATRIM®) was produced which is similar tothe article illustrated in FIG. 1, and described in detail herein. Thediaper was a “Step 6” size, configured to fit an infant having a weightof over 35 lbs. The diaper was positioned in its completely unfoldedconfiguration, as described in Example 1A. As disclosed in Table 1, thediaper was measured to have an area or “footprint” of 265.52 inches².The diaper was folded into the “S” folded configuration illustrated inFIG. 7 by hand, and it was measured in the same manner as described inExample 1A.

[0144] As disclosed in Table 1, the width was 4.500 inches and thelength was 3.750 inches. The area or “footprint” was 16.88 inches². Thecalculated depth was 1.197 inches. The volume was 20.199 inches³. Theratio of the footprint of the “S” folded diaper compared to its unfoldedfootprint was 0.064.

Example 7E

[0145] A diaper (HUGGIES® ULTRATRIM®) was produced which is similar tothe article illustrated in FIG. 1, and described in detail herein. Thediaper was a “Step 6” size, configured to fit an infant having a weightof over 35 lbs. The diaper was positioned in its completely unfoldedconfiguration, as described in Example 1A. As disclosed in Table 1, thediaper was measured to have an area or “footprint” of 265.52 inches².The diaper was folded into the “Pretzel” folded configurationillustrated in FIG. 8 by hand, and it was measured in the same manner asdescribed in Example 1A.

[0146] As disclosed in Table 1, the width was 4.500 inches and thelength was 2.500 inches. The area or “footprint” was 11.25 inches². Thecalculated depth was 1.596 inches. The volume was 17.955 inches³. Theratio of the footprint of the “Pretzel” folded diaper compared to itsunfolded footprint was 0.042. TABLE 2 Training Pant Dimensions HUGGIES ®PULL-UPS ® Training Pants (Size = Large) DIMENSIONS (Examples 8A-8D) W LD AREA(in²) VOLUME(in³) *RATIO FLAT/UNFOLDED 182.375 BIFOLD (8A) 4.37510.100 0.532 44.19 23.508 0.242 TRIFOLD (N/A)** — — — — — — QUADRIFOLD(8B) 4.375 4.750 1.063 20.78 20.090 0.114 S-FOLD (8C) 4.375 3.250 1.59514.22 22.679 0.078 PRETZEL FOLD (8D) 4.375 2.500 2.126 10.94 23.2530.060

Example 8A

[0147] A training pant (HUGGIES® PULL-UPS®, available fromKimberly-Clark Corporation, Neenah, Wis.) was produced which is similarto the article illustrated in FIG. 1 and described in detail herein,except that it is an underwear-type of garment for a young child, asshown in FIG. 12. The training pant was a “large” size. The trainingpant was positioned in its unfolded configuration. That is, the trainingpant was cut on each side from leg opening to waist opening, and laidflat with unretracted elastics and extended to ungathered lengthconfiguration, and measured as described previously in detail in Example1A. As disclosed in Table 2, the training pant was measured to have anarea or “footprint” of 182.375 inches². The area was determined asdescribed previously in Example 1A

[0148] An identical uncut training pant, which in its configuration asunderwear has a pre-existing bifold (front and back panel seamed on eachside) configuration was measured. That is the training pant waspositioned on a planar surface and restrained by hand, if necessary, inthe position, while the length measurement 138 and the width measurement140 were obtained and recorded.

[0149] The depth measurement 142 was obtained by measuring a standardpackaged bag of articles, that is, in this instance, a bag containingtraining pants. The height of the bag was divided by the total number ofpanels in a manner substantially similar that that described previouslyin Example 1A for diapers (training pants in the bag were packaged inthe bag horizontally relative to the top height of the bag). Thesenumbers were recorded. All measurements relating to training pants arein Tables 2 and 4.

[0150] As disclosed in Table 2, the width was 4.375 inches and thelength was 10.100 inches. The area or “footprint” was 44.19 inches². Thecalculated depth was 0.532 inches². The volume was 23.508 inches³. Theratio of the footprint of the folded training pant compared to itsunfolded footprint was 0.242.

Example 8B

[0151] A training pant diaper (HUGGIES® PULL-UPS® “large” size availablefrom Kimberly-Clark Corporation, Neenah, Wis.) was produced which issimilar to the article illustrated in FIG. 1, and described in detailherein, except that the article is an underwear-type garment for a youngchild., as shown in FIG. 12. The training pant was positioned in itscut-open laid flat configuration, as described in Example 1A. Asdisclosed in Table 2, the training pant was measured to have an area or“footprint” of 182.375 inches². The training pant was folded into thequadrifolded configuration illustrated in FIG. 6 by hand, and wasmeasured in the same manner as described in Example 1A.

[0152] As disclosed in Table 2, the width was 4.375 inches and thelength was 4.750 inches. The area or “footprint” was 20.78 inches². Thecalculated depth was 1.063 inches. The volume was 22.090 inches³. Theratio of the footprint of the folded training pant compared to itsunfolded footprint was 0.114.

Example 8C

[0153] A training pant diaper (HUGGIES® PULL-UPS® “large” size availablefrom Kimberly-Clark Corporation, Neenah, Wis.) was produced which issimilar to the article illustrated in FIG. 1, and described in detailherein, except that the article is an underwear-type garment for a youngchild, as shown in FIG. 12. The training pant was positioned in itscut-open laid flat configuration, as described in Example 1A. Asdisclosed in Table 2, the training pant was measured to have an area or“footprint” of 182.375 inches². The training pant was folded into the“S” configuration illustrated in FIG. 7 by hand, and was measured in thesame manner as described in Example 1A.

[0154] As disclosed in Table 2, the width was 4.375 inches and thelength was 3.250 inches. The area or “footprint” was 14.22 inches². Thecalculated depth was 1.595 inches. The volume was 22.679 inches³. Theratio of the footprint of the folded training pant compared to itsunfolded footprint was 0.078.

Example 8D

[0155] A training pant diaper (HUGGIES® PULL-UPS® “large” size availablefrom Kimberly-Clark Corporation, Neenah, Wis.) was produced which issimilar to the article illustrated in FIG. 1, and described in detailherein, except that the article is an underwear-type garment for a youngchild, as shown in FIG. 12. The training pant was positioned in itscut-open laid flat configuration, as described in Example 1A. Asdisclosed in Table 2, the training pant was measured to have an area or“footprint” of 182.375 inches². The training pant was folded into the“Pretzel” configuration illustrated in FIG. 8 by hand, and was measuredin the same manner as described in Example 1A.

[0156] As disclosed in Table 2, the width was 4.375 inches and thelength was 2.500 inches. The area or “footprint” was 10.94 inches². Thecalculated depth was 2.126 inches. The volume was 23.253 inches³. Theratio of the footprint of the folded training pant compared to itsunfolded footprint was 0.060. TABLE 3 Adult Incontinence Pant DimensionsDEPENDS ® Refastenable Under Wear (Size = Large) DIMENSIONS (Examples9A-9D) W L D AREA(in²) VOLUME(in³) *RATIO FLAT/UNFOLDED 562.08 BIFOLD(9A) 7.125 15.125 0.499 107.77 53.775 0.192 TRIFOLD (N/A)** — — — — — —QUADRIFOLD (9B) 7.125 10.250 0.998 73.03 72.885 0.130 S-FOLD (9C) 7.1255.275 1.497 37.58 56.264 0.068 PRETZEL FOLD (9D) 7.125 3.625 1.996 25.8351.553 0.046

[0157] TABLE 4 Depth Measurement of Panel(s) of Diapers, Training Pants,and Al Pants/Garments: HUGGIES ® Ultratrim ® Diapers Mechanical DiaperSize: Compression^(1,2,3) Preemie 0.1656 Step 1 0.1714 Step 2 0.1750Step 3 0.1771 Step 4 0.1875 Step 5 0.1917 Step 6 0.1995 HUGGIES ® 0.2658PULL-UPS ® Training Pants (Size = Large) DEPEND ® 0.2495 RefastenableUnderWear (Size = Large)

[0158] 1. This panel dimension was determined by measuring a standardbag of diapers HUGGIES®

[0159] Ultratrim® diapers containing bifolded diapers and dividing theheight of the bag by the total number of panels (diapers positionedhorizontally relative to the top height of the bag). Using this averageper panel thickness, the thickness of several fold configurations werecalculated by multiplying the average per panel thickness by the numberof panels in the given fold configuration.

[0160] 2. This panel dimension was determined by measuring a standardbag of HUGGIES® PULL-UPS® training pants containing bifolded constructedpants and dividing the height of the bag by the total number of panels(training pants positioned horizontally relative to the top height ofthe bag). Using this average per panel thickness, the thickness ofseveral fold configurations were calculated by multiplying the averageper panel thickness by the number of panels in the given foldconfiguration.

[0161] 3. This panel dimension was determine by measuring a standard bagof DEPEND® Refastenable UnderWear containing bifolded constructedgarments and dividing the height of the bag by the total number ofpanels (garments positioned horizontally relative to the top height ofthe bag). Using this average per panel thickness, the thickness ofseveral fold configurations were calculated by multiplying the averageper panel thickness by the number of panels in the given foldconfiguration.

Example 9A

[0162] An adult incontinence garment “pant” (DEPEND® RefastenableDisposable Underwear, size “large”, available from Kimberly-ClarkCorporation, Neenah, Wis.) was produced which is similar to the articleillustrated in FIG. 1, and described in detail herein, except that it isan underwear-type of garment for an adult, as shown in FIG. 13. Thegarment was positioned in its unfolded configuration. That is, theunderwear garment was cut on each side from leg opening to waistopening, and laid flat with unretracted elastics and extended toungathered length configuration, and measured as described previously indetail in Example 1A. As disclosed in Table 3, the garment was measuredto have an area or “footprint” of 562.08 inches². The area wasdetermined as described previously in Example 1A.

[0163] An identical uncut garment, which in its configuration asunderwear has a pre-existing bifold (front and back panel formed on eachanterior and posterior side) configuration was measured. That is thegarment was positioned on a planar surface and restrained by hand, ifnecessary, in the position, while the length measurement 138 and thewidth measurement 140 were obtained and recorded. The depth measurement142 was obtained by measuring a standard packaged bag of articles, thatis, in this instance, a bag containing the adult garment describedherein. The height of the bag was divided by the total number of panelsin a manner substantially similar that that described previously inExample 1A for diapers (the garments in the bag were packaged in the baghorizontally relative to the top height of the bag). These numbers wererecorded. All measurements relating to the adult garment are in Tables 3and 4.

[0164] As disclosed in Table 3, the width was 7.125 inches and thelength was 15.125 inches. The area or “footprint” was 107.77 inches².The calculated depth was 0.499 inches². The volume was 53.775 inches³.The ratio of the footprint of the bifolded garment compared to itsunfolded footprint was 0.192.

Example 9B

[0165] An adult incontinence garment “pant” (DEPEND® RefastenableDisposable Underwear, size “large”, available from Kimberly-ClarkCorporation, Neenah, Wis.) was produced which is similar to the articleillustrated in FIG. 1, and described in detail herein, except that it isan underwear-type of garment for an adult, as shown in FIG. 13. Thegarment was positioned in its cut-open laid flat configuration, asdescribed in Example 1A. As disclosed in Table 3, the garment wasmeasured to have an area or “footprint” of 562.08 inches². The garmentwas folded into the quadrifolded configuration illustrated in FIG. 6 byhand, and was measured in the same manner as described in Example 1A.

[0166] As disclosed in Table 3, the width was 7.125 inches and thelength was 10.250 inches. The area or “footprint” was 73.03 inches². Thecalculated depth was 0.998 inches. The volume was 72.885 inches³. Theratio of the footprint of the folded garment compared to its unfoldedfootprint was 0.130.

Example 9C

[0167] An adult incontinence garment “pant” (DEPEND® RefastenableDisposable Underwear, size “large”, available from Kimberly-ClarkCorporation, Neenah, Wis.) was produced which is similar to the articleillustrated in FIG. 1, and described in detail herein, except that it isan underwear-type of garment for an adult, as shown in FIG. 13. Thegarment was positioned in its cut-open laid flat configuration, asdescribed in Example 1A. As disclosed in Table 3, the garment wasmeasured to have an area or “footprint” of 562.08 inches². The garmentwas folded into the “S” folded configuration illustrated in FIG. 7 byhand, and was measured in the same manner as described in Example 1A.

[0168] As disclosed in Table 3, the width was 7.125 inches and thelength was 5.275 inches. The area or “footprint” was 38.30 inches². Thecalculated depth was 1.497 inches. The volume was 56.264 inches³. Theratio of the footprint of the “S” folded garment compared to itsunfolded footprint was 0.068.

Example 9D

[0169] An adult incontinence garment “pant” (DEPEND®) RefastenableDisposable Underwear, size “large”, available from Kimberly-ClarkCorporation, Neenah, Wis.) was produced which is similar to the articleillustrated in FIG. 1, and described in detail herein, except that it isan underwear-type of garment for an adult, as shown in FIG. 13. Thegarment was positioned in its cut-open laid flat configuration, asdescribed in Example 1A. As disclosed in Table 3, the garment wasmeasured to have an area or “footprint” of 562.08 inches². The garmentwas folded into the “Pretzel” folded configuration illustrated in FIG. 8by hand, and was measured in the same manner as described in Example 1A.

[0170] As disclosed in Table 3, the width was 7.125 inches and thelength was 3.625 inches. The area or “footprint” was 25.83 inches². Thecalculated depth was 1.996 inches. The volume was 51.553 inches³. Theratio of the footprint of the folded garment compared to its unfoldedfootprint was 0.046.

[0171] Test

[0172] This invention is further illustrated by the following tests,which are not intended to limit the scope of the invention. Thefollowing test materials and test methods used to evaluate individualsamples of the compressed absorbent articles of the present inventionare set forth below.

[0173] A confidential, non-public test measuring absorbency of acompressed absorbent article compared to an identical non-compressedabsorbent article was conducted. Nine (9) participant caregivers, eachwith a child using a HUGGIES® ULTRATRIM® Step 3 size (16 lbs. to 28lbs.) diapers, were provided with fifteen (15) non-compressed HUGGIESULTRATRIM® Step 3 diapers in a large plastic bag. The caregivers werealso given fifteen (15) HUGGIES® ULTRATRIM® Step 3 diapers which hadbeen “S” folded, as illustrated in FIG. 7, and which had been vacuumpackaged, similarly as described in Example 1 (the individual vacuumpackaged diapers were also provided to caregivers in a large plasticbag). The caregivers tested and compared each type of diaper, i.e., thecompressed individually packaged diapers against the non-compresseddiapers, for three (3) days at the rate of five (5) diapers per day.

[0174] The caregivers were interviewed after the six (6) day period oftesting both the currently available HUGGIES ULTRATRIM® Step 3 diapersand the compressed, vacuum packaged HUGGIES ULTRATRIM® Step 3 diapers.The participant caregivers indicated that no significant differenceswere noted between the un-compressed diapers and the compressed diapers.Occasional leakage of urine and bowel movement was noted with both theun-compressed diapers and the compressed diapers. Reasonable absorbencyand performance was noted with both types of diapers as well. Caregiversdid not rate one type of diaper as performing better than the other;both types (un-compressed and compressed) were considered to have anequal performance relative to absorbency and leakage.

[0175] While the invention has been described in detail with respect tospecific aspects thereof, it will be appreciated that those skilled inthe art, upon attaining an understanding of the foregoing, may readilyconceive of alterations to, variations of and equivalents to theseaspects. Accordingly, the scope of the present invention should beassessed as that of the appended claims and any equivalents thereto.

What is claimed is:
 1. A disposable absorbent article having a foldedconfiguration and an folded configuration, wherein a ratio between thefolded configuration and the unfolded configuration is less than 0.09.2. The disposable absorbent article of claim 1, wherein the article ispositioned and sealed in a package, and the article has a configurationin the package which is smaller in at least two dimensions than theun-packaged folded article.
 3. The disposable absorbent article of claim2, wherein the article is vacuum packaged.
 4. The disposable absorbentarticle of claim 2, wherein the article is maintained prior to andduring packaging at a moisture content of less than 10 percent.
 5. Thedisposable absorbent article of claim 4, wherein the article ismaintained and packaged at a moisture content of less than 5 percent. 6.The disposable absorbent article of claim 5, wherein the article ismaintained and packaged at a moisture content of less than 3 percent. 7.The disposable absorbent article of claim 2, wherein the article ispackaged in a package having a gas permeability range of less than about3.0 cc/100 in²/24 hours to about 0.10 cc/100 in²/24 hours.
 8. Thedisposable absorbent article of claim 7, wherein the article is packagedin a package having a gas permeability range of less than about 2.0cc/100 in²/24 hours to about 0.10 cc/100 in²/24 hours.
 9. The disposableabsorbent article of claim 1 wherein the article is a diaper.
 10. Thedisposable absorbent article of claim 1, wherein the article is atraining pant.
 11. The disposable absorbent article of claim 1, whereinthe article is an adult incontinence garment.
 12. A compact packageddisposable absorbent article, comprising: a disposable absorbent articlehaving a folded configuration and an folded configuration, wherein aratio between the folded configuration and the unfolded configuration isless than 0.12; and a package having a gas permeability in a range ofless than about 5.0 cc/100 in²/24 hours to about 0.05 cc/100 in²/24hours, wherein the disposable absorbent article is folded to have morethan three overlapping folds in its folded configuration, and it ismaintained and packaged in the package at a moisture content of lessthan 5 percent.
 13. The compact packaged disposable absorbent article ofclaim 12 wherein the article is vacuum packaged.
 14. The compactpackaged disposable absorbent article of claim 12 wherein the article isa single packaged article.
 15. The compact packaged disposable absorbentarticle of claim 14, wherein the article is a diaper.
 16. The compactpackaged disposable absorbent article of claim 14, wherein the articleis a training pant.
 17. The compact packaged disposable absorbentarticle of claim 14, wherein the article is an adult incontinencegarment.
 18. The compact packaged disposable absorbent article of claim14, wherein a plurality of single packaged articles are releasablycoupled together.
 19. The compact packaged disposable absorbent articleof claim 12, wherein the article is maintained and packaged at amoisture level of less than 3 percent.
 20. The compact packageddisposable absorbent article of claim 12, wherein the package isselected from the group consisting of a blister package, an injectionmolded package, and a form-fill-seal package.
 21. A compact packageddisposable absorbent article, comprising: a disposable absorbent articlehaving a folded configuration and an unfolded configuration, wherein aratio between the folded configuration and the unfolded configuration isless than 0.12; and a package having a low degree of gas permeabilityand a pull tab, the package configured to remain in one piece afterbeing opened and having the article removed therefrom, wherein thearticle is maintained and packaged at a moisture content of less thanabout 3 percent such that when the article is positioned and sealed inthe package, the article has a configuration in the package which is atleast 30 percent less in volume than an un-packaged identically foldedarticle.
 22. The compact packaged disposable absorbent article of claim21 wherein the article is a single packaged article.
 23. The compactpackaged disposable absorbent article of claim 22, wherein the articleis a diaper.
 24. The compact packaged disposable absorbent article ofclaim 22, wherein the article is a training pant.
 25. The compactpackaged disposable absorbent article of claim 22, wherein the articleis an adult incontinence garment.
 26. The compact packaged disposableabsorbent article of claim 21, wherein the article is packaged in apackage having a gas permeability range of less than about 5.0 cc/100in²/24 hours to about 0.05 cc/100 in²/24 hours.
 27. The compact packageddisposable absorbent article of claim 26, wherein the article ispackaged in a package having a gas permeability range of less than about3.0 cc/100 in²/24 hours to about 0.10 cc/100 in²/24 hours.
 28. Thecompact packaged disposable absorbent article of claim 27, wherein thearticle is packaged in a package having a gas permeability range of lessthan about 2.0 cc/100 in²/24 hours to about 0.10 cc/100 in²/24 hours.29. The compact packaged disposable absorbent article of claim 21,wherein the package is selected from the group consisting of a blisterpackage, an injection molded package, and a form-fill-seal package. 30.The compact packaged disposable absorbent article of claim 21 whereinthe article is vacuum packaged.